Surgical stapler with small diameter endoscopic portion

ABSTRACT

A surgical stapler includes a body portion and a tool assembly. The body portion includes a large diameter portion and a small diameter portion extending distally from the large diameter portion. The large diameter portion supports larger internal components of the device including a lockout assembly adapted to prevent refiring of the stapler to allow the diameter of the small diameter portion of the device to be minimized to facilitate passage of the small diameter portion of the stapler and the tool assembly through an 8 mm trocar.

BACKGROUND Technical Field

The present disclosure relates to surgical staplers, and, moreparticularly, to endoscopic surgical staplers including small diameterendoscopic portions suitable for performing endoscopic surgicalprocedures including, inter alia, pediatric and thoracic surgicalprocedures.

Background of Related Art

Surgical staplers that effect simultaneous dissection and suturing oftissue are well known in the art. The advent of surgical staplers hasincreased the speed of tissue suturing and thus, increased the speed ofsurgical procedures to reduce patient trauma.

Endoscopic surgical staplers for suturing tissue endoscopically throughsmall incisions in the skin or through a cannula rather than byperforming open surgical procedures are also well known in the art andhave also reduced patient trauma.

Typically endoscopic surgical staplers include an elongated body thatsupports a tool assembly. The elongated body and tool assembly(endoscopic portion) are dimensioned to pass through the small incisionin the skin or the cannula. It is advantageous to minimize thedimensions of the elongated body and the tool assembly to minimizetrauma to the patient. Thus, a continuing need exists for small diametersurgical staplers suitable for endoscopic use.

SUMMARY

In accordance with the present disclosure, a surgical stapler isprovided that includes a body portion that has a distal portion of areduced diameter to facilitate insertion of the endoscopic portionthrough a small diameter trocar assembly. In embodiments, the surgicalstapler includes an actuation device, and a stapler reload releasablysecured to the actuation device. The stapler reload includes a bodyportion, a tool assembly, and a drive assembly extending between thebody portion and the tool assembly. The body portion includes a largediameter portion defining a first diameter and a small diameter portiondefining a second diameter extending distally from the large diameterportion. The tool assembly is supported on a distal portion of the smalldiameter portion. The small diameter portion is dimensioned to passthrough an 8 mm trocar. The surgical stapler further includes a shippinglock releasably secured to the large diameter portion of the bodyportion and engagable with the drive assembly for preventinglongitudinal movement of the drive assembly. The shipping lock mayinclude curved arms configured to frictionally engage the body portionof the stapler reload

In embodiments, the tool assembly includes an anvil assembly and acartridge assembly supporting a plurality of staples and the driveassembly is movable through the body portion and the tool assembly toeject staples from the cartridge assembly. The drive assembly mayinclude a drive member and the shipping lock may include a locking pin.The locking pin may be received through the drive member when theshipping lock is secured to the body portion to prevent longitudinalmovement of the drive member.

In embodiments, the surgical stapler may further include a lockingplate. The locking plate may engage the locking pin prior to the staplerreload being secured to the actuation device. The locking plate may beconfigured to disengage from the locking pin when the stapler reload isproperly secured to the actuation device.

In embodiments, the surgical stapler may also include a locking sleevereceived about a proximal portion of the body portion of the staplerreload. Rotation of the locking sleeve from a first position to a secondposition may move the locking plate out of engagement with the lockingpin. The locking sleeve may rotate from the first position to the secondposition when the stapler reload is properly secured to the actuationdevice.

In embodiments, the surgical stapler includes an actuation device, astapler reload releasably secured to the actuation device, and a lockoutassembly. The stapler reload includes a body portion, a tool assembly,and a drive assembly extending between the body portion and the toolassembly. The body portion includes a large diameter portion defining afirst diameter and a small diameter portion defining a second diameterextending distally from the large diameter portion. The tool assembly issupported on a distal portion of the small diameter portion. The smalldiameter portion is dimensioned to pass through an 8 mm trocar. Thelockout assembly is configured to prevent advancement of the driveassembly following an actuation of the stapler reload. The lockoutassembly includes a lockout shield and a lockout member. The lockoutshield is movable from a first position to a second position to preventengagement of the lockout member with the drive assembly prior to theactuation of the stapler reload, wherein the lockout member engages thedrive assembly when the lockout shield is in the second position.

In embodiments, the drive assembly may include a drive member having aridge, wherein the lockout member is engagable with the ridge when thelockout shield is in the second position. The lockout shield may bedisposed about the ridge when in the first position and may be spacedfrom the ridge when in the second position. The lockout shield may bedisposed within the large diameter portion when in the first positionand is disposed within the small diameter portion when in the secondposition. The lockout shield may include at least one lance and thelarge diameter portion may include a housing. The lance may beconfigured to engage the housing when in the second position to preventproximal movement of the lockout shield.

In embodiments, the lockout member may be pivotally supported within thebody portion between a first condition in engagement with the drivemember and a second condition disengaged from the drive member. Thelockout member may include at least one finger frictionally engaged withthe drive member when the lockout shield is in the first position tomaintain the lockout shield in the first position.

BRIEF DESCRIPTION OF THE DRAWINGS

Various embodiments of the presently disclosed surgical stapler withsmall diameter endoscopic portion are described herein with reference tothe drawings, wherein:

FIG. 1 is a side, perspective view of an embodiment of the presentlydisclosed surgical stapler with a small diameter endoscopic portionincluding a stapler reload and an adapter assembly secured to a handleassembly, with a tool assembly of the stapler reload in an open,non-articulated position;

FIG. 2 is a side, perspective view of an adapter assembly secured to apowered actuation device for use with the stapler reload of FIG. 1;

FIG. 3 is a first side perspective view of the stapler reload shown inFIG. 2;

FIG. 4 is a second side perspective view of the stapler reload shown inFIG. 2;

FIG. 5 is an exploded perspective view of the stapler reload shown inFIG. 2;

FIG. 6 is a cross-sectional view taken along section line 6-6 of FIG. 3;

FIG. 7 is an enlarged view of the indicated area of detail shown in FIG.6;

FIG. 8 is a cross-sectional view taken along section line 8-8 of FIG. 7;

FIG. 9 is a cross-sectional view taken along section line 9-9 of FIG. 8;

FIG. 10 is a perspective view of a large diameter portion of a bodyportion of the stapler reload of FIG. 1, with an upper half-sectionremoved and a rotatable sleeve in a first or locked position;

FIG. 11 is a cross-sectional view taken along section line 11-11 of FIG.7;

FIG. 12 is a side perspective view of the large diameter portion shownin FIG. 10 with an outer tube removed and the rotatable sleeve in thefirst position;

FIG. 13 is a side perspective view of the large diameter portion shownin FIG. 10 with the outer tube removed and the rotatable sleeve in asecond or unlocked position;

FIG. 14 is a cross-sectional view taken along section line 14-14 of FIG.7, with a locking member in a proximal position and a shipping locksecured to the body portion of the stapler reload;

FIG. 15 is a cross-sectional view taken along section line 15-15 shownin FIG. 7, with the locking member in a distal position as the shippinglock is being released from the body portion of the stapler reload;

FIG. 16 is a cross-sectional view taken along section line 16-16 shownin FIG. 7, with the shipping lock removed;

FIG. 17 is a cross-sectional view taken along section line 17-17 shownin FIG. 11;

FIG. 18 is a perspective view of the large diameter portion shown inFIG. 10, with the upper half-section removed and the rotatable sleeve inthe second position;

FIG. 19 is a perspective top view of the large diameter portion shown inFIG. 18, with a lockout assembly in a first or unlocked condition;

FIG. 20 is a cross-sectional view of the large diameter portion shown inFIG. 19, subsequent to actuation of the stapler reload;

FIG. 21 is a perspective top view of the large diameter portion shown inFIG. 19, subsequent to actuation of the stapler reload;

FIG. 22 is a perspective view of the large diameter portion shown inFIG. 21, during a second actuation of the stapler reload;

FIG. 23 is a perspective top view of a proximal portion of the largediameter portion shown in FIGS. 18-21, with a lockout member and lockoutmember tool shown in phantom;

FIG. 24 is a cross-sectional top view of the stapler reload shown inFIGS. 1 and 2;

FIG. 25 is a cross-sectional top view of the large diameter portionshown in FIGS. 18-21, prior to actuation of the stapler reload;

FIG. 26 is a cross-sectional top view of a small diameter portion of thestapler reload shown in FIGS. 1 and 2;

FIG. 27 is a perspective view of a proximal portion of an inner body ofthe small diameter portion shown in FIG. 26;

FIG. 28 is a perspective view of the proximal portion of the inner bodyshown in FIG. 27, with the outer tube removed;

FIG. 29 is an enlarged perspective view of a pnuematic seal according toan embodiment of the present disclosure;

FIG. 30 is a perspective view of an articulating portion of thepresently disclosed stapler reload including a mounting assembly;

FIG. 31 is a perspective view of a coupling member according to anembodiment of the present disclosure;

FIG. 32 is a perspective view of the coupling member shown in FIG. 31and an upper mounting bracket of the mounting assembly shown in FIG. 30;

FIG. 33 is a perspective view of the coupling member and upper mountingbracket shown in FIG. 32, prior to locking the coupling member to theupper mounting bracket;

FIG. 34 is a perspective view of the coupling member and upper mountingbracket shown in FIGS. 32 and 33, subsequent to locking the couplingmember to the upper mounting bracket;

FIG. 35 is an enlarged section view of the indicated area of detailshown in FIG. 5;

FIG. 36 is a perspective view of the articulating portion of the staplerreload shown in FIG. 30 with the upper mounting bracket of the mountingassembly and the cartridge assembly removed;

FIG. 37 is a perspective view of the tool assembly the stapler reloadshown in FIGS. 1 and 2;

FIG. 38 is a perspective, top view of the distal portion of the smalldiameter portion of the stapler reload shown in FIGS. 1 and 2, with theupper mounting bracket and upper housing half-section removed;

FIG. 39 is a perspective, side view of the articulating portion of thestapler reload shown in FIG. 30, with the outer tube of the body portionand the channel of the cartridge assembly removed;

FIG. 40 is a perspective view of the tool assembly shown in FIG. 37,with the channel of the cartridge assembly removed;

FIG. 41 is a perspective view of the cartridge assembly shown in FIG.40, with parts separated;

FIG. 42 is a perspective, top view of the body portion of the staplerreload shown in FIGS. 1 and 2, with the upper housing half-section andproximal tube body removed;

FIG. 43 is a perspective view of the articulating portion of the staplerreload shown in FIG. 30, with the outer tube of the small diameterportion removed; and

FIG. 44 is a perspective view of the assembled articulating portion ofthe stapler reload shown in FIG. 43.

DETAILED DESCRIPTION OF EMBODIMENTS

Embodiments of the presently disclosed surgical stapler with a smalldiameter endoscopic portion will now be described in detail withreference to the drawings wherein like reference numerals designateidentical or corresponding elements in each of the several views. Inthis description, the term “proximal” is used generally to refer to theportion of the apparatus that is closer to a clinician, while the term“distal” is used generally to refer to the portion of the stapler thatis farther from the clinician. In addition, the term “endoscopic” isused generally to refer to surgical procedures performed through a smallincision or a cannula inserted into a patient's body includingendoscopic, laparoscopic and arthroscopic surgical procedures. Finally,the term clinician is used generally to refer to medical personnelincluding doctors, nurses, and support personnel.

FIG. 1 illustrates an embodiment of the presently disclosed smalldiameter reload is shown generally as stapler reload 100. The staplerreload 100 is part of a surgical stapling device 10 including a handleassembly or actuation device 20. In embodiments, the stapler reload 100may be integrally formed with the handle assembly 20. As shown, thehandle assembly 20 includes a handle 22, a trigger member 24 pivotallysecured to the handle 22, and a pair of firing levers 26 (only oneshown) extending from the handle 22, and an elongated body 28 rotatablysecured to the handle 22 and including an articulating lever 28 a. For adetailed description of an exemplary handle assembly, please refer tocommonly owned U.S. Pat. No. 8,070,033, the content of which isincorporated herein by reference in its entirety.

Turning briefly to FIG. 2, it is envisioned that the stapler reload 100may be operated with a powered handle assembly 20A. As shown, an adapterassembly 30A is secured to the powered handle assembly 20A and thestapler reload 100 is secured to the adapter assembly 30A. It isenvisioned that the adapter assembly 30A and the stapler reload 100(FIG. 1) and/or the handle assembly 20A can be integrally formed suchthat the stapler reload 100 is non-releasably supported on, or forms anintegral extension of, the adapter assembly 30A and/or the handleassembly 20A. For a detailed description of exemplary handle assembliesand adapter assemblies, please refer to commonly owned U.S. PatentApplication Publication No. 2012/0253329 (“the '329 publication”), thecontent of which is incorporated by reference herein in its entirety.

Referring to FIGS. 3 and 4, the stapler reload 100 includes a bodyportion 102, a mounting assembly 104, and a tool assembly 106. The bodyportion 102 defines a longitudinal axis “x” that is aligned with thelongitudinal axis of the adapter assembly 30 (FIG. 1) and has a couplingportion 108, a large diameter portion 110, and an endoscopic or smalldiameter portion 112. The large diameter portion 110 of the staplerreload 100 has a diameter greater than the diameter of the smalldiameter portion 112. In embodiments, the small diameter portion 112 ofthe stapler reload 100 is dimensioned to be received in an 8 mm trocarassembly (not shown), whereas the large diameter portion 110 is about 12mm in diameter and dimensioned to support a lock assembly 200 and alockout assembly 220, as discussed in detail below.

The tool assembly 106 includes an anvil assembly 114 and a cartridgeassembly 116. In embodiments, the cartridge assembly 116 is pivotallysupported in relation to the anvil assembly 114 and is movable betweenan open position (FIG. 2) and a closed or approximated position (FIG.39). Alternately, the anvil 114 can be pivotally coupled to thecartridge assembly 116. The mounting assembly 104 is supported on adistal portion of the body portion 102 and pivotally supports the toolassembly 106 to facilitate articulation of the tool assembly 106 aboutan axis perpendicular to the longitudinal axis “x” of the body portion102 between an articulated position in which a longitudinal axis of thetool assembly 106 defines an acute angle with the longitudinal axis “x”of the body portion 102 and a non-articulated position in which thelongitudinal axes of the tool assembly 106 and the body portion 102 arealigned.

Referring to FIG. 5, the large diameter portion 110 of the body portion102 of the stapler reload 100 includes an inner housing 120 having anupper housing half-section 120 a and a lower housing half-section 120 bthat are secured relative to each other with a tab and slotconfiguration as shown, or in any other suitable manner. The upper andlower housing half-sections 120 a, 120 b define channels 121 a, 121 bwhich slidably receive a drive member 124 and a first articulation link126. The upper and lower housing half-sections 120 a, 120 b are receivedwithin a proximal body tube 128 that prevents separation of the halfsections 120 a, 120 b.

The proximal portion of the upper housing half-section 120 a defines thecoupling portion 108 and includes engagement nubs 130 for releasablyengaging the distal portion of the adapter assembly 30 (FIG. 1) in abayonet-type coupling arrangement. For a detailed description of anexemplary coupling portion please refer to commonly owned U.S. Pat. No.5,865,361 (“the '361 patent”), the content of which is incorporatedherein by reference in its entirety.

An electrical connector assembly 122 is supported within the proximalportion of the upper housing half-section 120 a of the body portion 102of the stapler reload 100. The connector assembly 122 includes aconnector base 122 a and a contact member 122 b. For a detaileddiscussion of an exemplary electrical connection assembly, please referto commonly own U.S. Pat. App. Pub. No. 2016/0249929, the content ofwhich is incorporated by reference herein in its entirety.

The drive member 124 of the stapler reload 100 includes a proximalportion that supports a drive block 132. The drive block 132 isconfigured to releasably engage a control rod 32 (FIG. 2) of the adapterassembly 30 (FIG. 2) to translate movement of the control rod 32 intomovement of the drive member 124. The drive block 132 is operablyengaged by a locking sleeve 134 to prevent firing of the stapler reload100 prior to the stapler reload 100 being properly secured to adapterassembly 20 (FIG. 1). A distal portion of the drive member 124 defines aslot 125 that engages a hooked proximal portion of a drive assembly 136such that distal movement of the drive member 124 effects distalmovement of the drive assembly 136.

By providing the stapler reload 100 with a large diameter portion 110for housing the drive block 132 and the locking sleeve 134, as well asother components of the stapler 10 described below, the diameter of thesmall diameter portion 112 can be minimized, for example, to about 8 mmsuch that it can be received within an 8 mm trocar assembly (not shown).The large diameter portion 110 can be about 12 mm in diameter or larger.

Referring still to FIG. 5, the first articulation link 126 defines ahooked proximal portion 126 a that is configured to engage anarticulation shaft (not shown) of the adapter assembly 30 (FIG. 1) whenthe stapler reload 100 is secured to the adapter assembly 30. A distalportion 126 b of the first articulation link 126 engages a proximalportion 138 a of a second articulation link 138. Although shown having ahook and notch configuration and a corresponding slotted configuration,the respective distal portion 126 b of the first articulation link 126and the proximal portion 138 a of the second articulation link 138 maybe secured to one another in any suitable manner.

The proximal portion 138 a of the second articulation link 138 isslidably positioned within the large diameter portion 110 of the bodyportion 102 of the stapler reload 100. The distal portion 138 b of thesecond articulation link 138 engages a first articulation member 140 awhich is pivotally connected to a lower mounting bracket 142 of themounting assembly 104 at a location offset from the longitudinal axis ofthe body portion 102 such that longitudinal movement of the secondarticulation link 138 effects pivotal movement of the tool assembly 106about the longitudinal axis.

The small diameter portion 112 of the body portion 102 of the staplerreload 100 includes an inner body 144 having upper and lowerhalf-sections 144 a, 144 b that are received within an outer tube 146.The upper and lower half-sections 144 a, 144 b define a first channel143 a that slideably receives the drive member 124 and the driveassembly 136. The upper and lower half-sections 144 a, 144 b also definea second channel 143 b that slideably receives the second articulationlink 138. Respective distal ends of the upper and lower half-sections144 a, 144 b also define cutouts 145 a, 145 b. The outer tube 146includes a proximal flange 146 a for securing the outer tube 146 to theupper and lower housing half-section 120 a, 120 b of the large diameterportion 110 of the body portion 102. The outer tube 146 defines openings147 a, 147 b (FIG. 20) for receiving respective protrusions 230 a, 230 b(FIG. 20) of respective upper and lower housing half-sections 120 a, 120b.

As noted above, the tool assembly 106 includes the anvil assembly 114and the cartridge assembly 116. The anvil assembly 114 includes an anvilbody 150 and an anvil cover 152 which is secured to the topside of theanvil body 150 to define a channel (not shown). In embodiments, staplepockets 151 are formed directly into the anvil body 150. Alternatively,the anvil body 150 may be provided with an anvil plate (not shown). Inembodiments, the anvil body 150 may be one-piece, e.g., monolithic. Inembodiments, the staple pockets may be formed using micro-electrolyticdissolution (MED). In embodiments, the anvil body 150 may include alubricated hard coating.

In embodiments, a dissector tip 154 is supported on the distal portionof the anvil body 150. The anvil body 150 defines plurality of staplereceiving depressions 151 (FIG. 37) and a longitudinal slot 153 which isdimensioned to slideably receive a portion of a working portion 156 ofthe drive assembly 136 of the stapler reload 100. A proximal portion ofthe anvil body 150 includes a bracket 150 a defining a hole 157 forreceiving a pivot member or boss 162 a of an upper mounting bracket 162of the mounting assembly 104.

In embodiments, the tissue dissector 154 is secured to a distal portionof the anvil assembly 114 with friction fit, adhesives, welding,mechanical fasteners, or in any suitable manner. The tissue dissector154 has a tapered configuration and extends distally of the distalportion of the cartridge assembly 116 to allow the tool assembly 106 tobe manipulated about tissue adjacent a surgical site. The tissuedissector 154 may be attached to the distal portion of the anvilassembly 114, as shown, or may be integrally and/or monolithicallyformed with the anvil assembly 114. Alternately, the tissue dissector154 may be attached to the cartridge assembly 116. In addition, theanvil assembly 114 may include a buttress material (not shown) tostrengthen tissue being sutured and dissected as is known in the art.

In some embodiments, the cartridge assembly 116 includes a channel 164and a staple cartridge 166 that is received within the channel 164. Itis envisioned that the staple cartridge 166 may be attachable to thechannel 164 by a snap-fit connection, or in any suitable manner, and maybe removable to permit replacement following a stapling procedure. For adetailed description of an exemplary replaceable staple cartridgeassembly, please refer commonly owned U.S. Pat. App. Pub. No.2012/0286021, the content of which is incorporated herein by referencein its entirety.

The channel 164 is pivotally secured to the anvil body 150 by pivot pins168 which extend through openings 151 a formed in the anvil body 150 andopenings 151 b formed in the channel 164. The staple cartridge 166includes a cartridge body 170 which may define only two rows of stapleretention slots 171 a on each side of a knife slot 171 b to facilitatereduction in the diameter of the tool assembly 106. The knife slot 171 bis aligned with an elongated slot 165 defined in the channel 164 tofacilitate passage of a dynamic clamping member 156 a. The stapleretention slots 171 a are positioned along a tissue contact surface ofthe cartridge body 170 and are aligned with the staple formingdepressions 151 (FIG. 37) of the anvil body 150. Each staple retentionslot 171 a is configured to receive a fastener or staple “S” and apusher 174. A cartridge shield 172 allows the pushers 174 to float, andprevents the pushers 174 from exiting a respective staple retention slot171 a during transport and prior to use. An actuation sled 176 ispositioned to pass longitudinally through the cartridge body 170 intoengagement with the pushers 174 to sequentially eject the staples “S”from the cartridge body 170. For a detailed description of an exemplarycartridge assembly, please refer to commonly owned U.S. Pat. App. Pub.No. 2013/0098965 (“the '965 publication”), the content of which isincorporated by reference herein in its entirety.

The mounting assembly 104 includes the upper mounting bracket 162 andthe lower mounting member 142. Each of the upper and lower mountingbrackets 162, 142 includes a pivot member or boss 162 a, 142 a (FIG.33), respectively. As discussed above, the pivot member 162 a isreceived within the hole 157 of the bracket 150 a of the anvil body 150to secure the upper mounting bracket 162 to the anvil body 150. A firstcoupling member 178 has a first portion which defines an opening 179that also receives the pivot member 162 a and a second portion which isreceived within the cutout 145 a defined in the distal portion of theupper half-section 144 a of the small diameter portion 112 of the bodyportion 102 of the stapler reload 100. Pivot member 142 a on the lowermounting bracket 142 is received in an opening 181 defined in a firstportion of a second coupling member 180. The second coupling member 180has a second portion that is received within the cutout 145 b definedwithin lower housing half-section 144 b of the body portion 102 topivotally secure the lower mounting bracket 142 to the lower housinghalf-section 144 b of the inner body 140 of the body portion 102 of thestapler reload 100.

The pivot pins 168 extend through openings 151 a formed in the anvilbody 150 and openings 151 b formed in the channel 164, and are receivedin openings 141 formed in lower mounting bracket 142 to secure the lowermounting bracket 142 to the channel 164. The upper and lower mountingbrackets 162, 142 are secured together by pin members 182 a, 182 b.

Referring to FIGS. 5-13, a lock assembly 200 is supported on theproximal portion of large diameter portion 110 of the body portion 102of the stapler reload 100 to prevent axial movement of the driveassembly 136 until the stapler reload 100 is properly attached to theadapter assembly 30 (FIG. 1) of the surgical stapler 10 (FIG. 1). Thelock assembly 200 includes the drive block 132 supported on the proximalportion of the drive member 124 and the rotatable sleeve 134 isconfigured for selective engagement with the drive block 132 to preventlongitudinal movement of the drive member 124. The rotatable sleeve 134is mounted about the proximal portion of the housing 120 of the bodyportion 102, and includes two proximally extending fingers 202 a. Therotatable sleeve 134 also includes a distally extending flange 202 b. Alock plate 204 is slideably supported within a cutout 201 a of the lowerhousing half-section 120 b of the inner housing 120 of the body portion102 of the stapler reload 100, and is positioned to be engaged by thedistally extending flange 202 b of the rotatable sleeve 134 duringattachment of the stapler reload 100 to the adapter assembly 30 (FIG. 1)to prevent forward movement of the drive member 124.

The rotatable sleeve 134 also includes a blocking finger 202 c thatextends downwardly into the path of the drive block 132 to obstructmovement of the drive block 132 when the rotatable sleeve 134 is in afirst or locked position. When the rotatable sleeve 134 is rotated, asindicated by arrow “A” in FIGS. 11 and 13, the blocking finger 202 c ismoved from the first position (FIG. 8) in engagement with the driveblock 132 to a second position (FIG. 11) spaced from the drive block 132to facilitate longitudinal movement of the drive block 132 and, thus,drive member 124.

With particular reference to FIG. 7, when the rotatable sleeve 134 ispositioned about the proximal portion of the lower housing half-section120 b, the proximally extending fingers 202 a of the locking sleeve 134are positioned in alignment with the nubs 130 on the upper housinghalf-section 120 a. Each proximally extending finger 202 a includes aninwardly extending protrusion 203 that is received in a respectiverecess 205 formed on an outer surface of the upper half section 120 a toreleasably retain the sleeve 134 in the first position. When the staplerreload 100 is attached to an adapter assembly 30 (FIG. 1), the proximalportion of the stapler reload 100 is inserted into the distal portion ofthe adapter assembly 30 (FIG. 1) and rotated to engage the bayonet-typecoupling components of the stapler reload 100 and the adapter assembly30. As the adapter assembly 30 is rotated in relation to the staplerreload 100, a portion of the adapter assembly 30 engages the proximallyextending fingers 202 a of the rotatable sleeve 134 to rotate therotatable sleeve 134 about the inner housing 120 of the stapler reload100 from the first position (FIG. 8) to the second position (FIG. 11).

The stapler reload 100 is provided with a shipping lock 208 configuredto prevent operation of the stapler reload 100. The shipping lock 208 isselectively secured to the large diameter portion 110 of the bodyportion 102 of the stapler reload 100 and extends through an opening 123c in the drive member 124 to prevent axial movement of the drive member124. The shipping lock 208 is configured to be separated from the bodyportion 102 of the stapler reload 100 only after the stapler reload 100is properly secured to an actuation device 20 (FIG. 1).

As noted above, rotation of the rotatable sleeve 134 from the firstposition to the second position also causes the distally extendingflange 202 b of the rotatable sleeve 134 to engage the lock plate 204.With particular reference to FIGS. 12 and 13, the lock plate 204 isreceived within the cutout 201 of the lower housing half-section 120 band is configured to prevent release of the shipping lock 208 (FIG. 7)from engagement with the body portion 102 of the staple reload 100 untilthe staple reload 100 is properly secured to the adapter assembly 30(FIG. 1). More particularly, the lock plate 204 is biased proximally bya spring 210 and defines a lock slot 205 for releasably engaging alocking pin 212 of the shipping lock 208. The lock slot 205 includes asmall diameter portion 205 a sized to be received around a notchedportion 212 a (FIG. 7) of the locking pin 212 of the shipping lock 208,and a large diameter portion 205 b through which the entirety of thelocking pin 212 can be received.

During rotation of the rotatable sleeve 132, the distally extendingflange 206 of the rotatable sleeve 134 engages a cammed surface 204 a ofthe lock plate 204, causing the lock plate 204 to move in the distaldirection, as indicated by arrows “B” in FIG. 13, against the bias ofthe spring 210. As the lock plate 204 moves from a proximal position(FIG. 12) to a distal position (FIG. 13), the lock slot 205 is movedfrom having the small diameter portion 205 a positioned about thenotched portion 212 a of the locking pin 212 to having the largediameter portion 205 b received about the locking pin 212. With thenotched portion 212 a of the locking pin 212 positioned within the largediameter portion 205 b, the locking pin 212 can be withdrawn from thestapler reload 100. In this manner, distal movement of the lock plate204 permits release of the locking pin 212 of the shipping lock 208 fromengagement with the stapler reload 100.

Turning now to FIG. 14, the shipping lock 208 is shown secured to thelarge diameter portion 110 of the body portion 102 of the stapler reload100. In particular, curved arms 208 a of the shipping lock 208 arereceived about proximal body tube 128 of the large diameter portion 110of the body portion 102 and the locking pin 212 is received throughopenings in the upper and lower housing half-sections 120 a, 120 b ofthe housing 120, and through openings in a lockout shield 222 and thedrive member 124. In this manner, the drive member 124 is prevented fromlongitudinal movement in any direction. The notched portion 212 a of thelocking pin 212 is engaged by the lock plate 204 to prevent the shippinglock 208 from accidentally disengaging from the stapler reload 100 priorto the staple reload 100 being properly secured to the adapter assembly30 (FIG. 1).

With reference now to FIG. 15, during rotation of the rotatable sleeve134 during attachment of the stapler reload 100 to the adapter assembly30 (FIG. 1), the lock plate 204 is moved distally via engagement withthe flange 202 b of rotatable sleeve 134 (FIG. 13) to align the largeportion 205 b of the lock slot 205 with the locking pin 212 of theshipping lock 208. In this manner, the locking plate 204 is disengagedfrom within the locking pin 212 such that the locking pin 212 is nolonger secured to the body portion 102 of the stapler reload 100, andthe shipping lock 208 is free to be separated from the body portion 102of the stapler reload 100. A handle portion 208 b of the shipping lock208 is configured to be grasped and facilitate separation of theshipping lock 208 from the body portion 102. More particularly, thehandle portion 208 b permits a user to pull the shipping lock 208radially outward from the body portion 102 of the stapler reload 100 toovercome the spring force of the arms 208 a of the shipping lock 208 torelease the shipping lock 208 from the body portion 102 of the staplerreload.

Turning briefly to FIG. 16, once the shipping lock 208 (FIG. 15) isseparated from the stapler reload 100, the stapler reload 100 is readyfor use.

With reference now to FIGS. 5 and 18-23, the large diameter portion 110of the body portion 102 of the stapler reload 100 includes a lockoutassembly 220 to prevent subsequent advancement of the drive member 124following firing of the stapler reload 100. The lockout assembly 220includes a lockout shield 222 and a lockout member 224. The lockoutshield 222 is slideably disposed about a proximal portion of the drivemember 124 and includes a pair of proximally extending and outwardlybiased shield lances 226 a (FIGS. 19 and 20) and a pair of distallyextending shield fingers 226 b. The shield lances 226 a operate toprevent retraction of the lockout shield 222 subsequent to actuation ofthe stapler reload 100. The shield fingers 226 b engage a proximal setof notches 123 a (FIG. 5) of the drive member 124 prior to actuation ofthe stapler reload 100, i.e., before the lockout shield 222 is moveddistally (FIG. 17), to maintain the lockout shield 222 in engagementwith the drive block 132. Subsequent to advancement of the drive block132 and the lockout shield 222 (FIG. 21), the shield fingers 226 bengage a distal set of notches 123 b (FIG. 5) in the drive member 124(FIG. 17) to assist in retaining the drive member 124 subsequent toretraction of the drive member 134.

With particular reference to FIGS. 19 and 21, the lockout member 224 ispivotally supported within the inner housing 120 of the body portion 102and includes a proximal portion 224 a that is biased radially inward bya spring member, e.g., leaf spring 225, into engagement with the lockoutshield 222 prior to firing of the stapler reload 100 (FIG. 26) and intoengagement with the drive member 124 subsequent to retraction of thedrive member 124 following actuation of the stapler reload 100.

With particular reference to FIG. 20, during actuation of the staplerreload 100, engagement of the drive block 132 by the connector rod 32(FIG. 2) of the adapter assembly 30 (FIG. 2) causes the drive member 124and the lockout shield 222 to advance distally, as indicated by arrows“C” in FIG. 20. As the drive block 132 is advanced, the lockout shield222 is moved distally into the outer tube 146 of the small diameterportion 112 of the body portion 102 of the stapler reload 100. Once thelockout shield 222 is received within the outer tube 146, the shieldlances 226 a of the lockout shield 222 engage protrusions 230 a, 230 bformed on respective upper and lower housing half-sections 120 a, 120 bof housing 120. Engagement of the shield lances 226 a with theprotrusion 230 a, 230 b of the respective upper and lower housinghalf-sections 120 a, 120 b prevents proximal movement of the lockoutshield 222 as the drive member 124 is retracted to its initial positionsubsequent to the actuation stroke.

With particular reference now to FIG. 21, when the drive member 124returns to its initial position, subsequent to the actuation stroke ofthe stapler reload 100, as noted above, the lockout shield 222 remainswithin the outer tube 146 of the small diameter portion 110 of the bodyportion 102 of the stapler reload 100 because of the shield lances 226 aof the lockout shield 222 prevent proximal movement of the lockoutshield 222. Without the lockout shield 222 being received around theproximal portion of the drive member 124, the proximal portion 224 a ofthe lockout member 224 directly engages the drive member 124. During anysubsequent attempted actuations of the stapler reload 100 after theinitial actuation, the proximal portion 224 a of the lockout member 224will engage a flange 232 located distal of the proximal portion of thedrive member 124, thereby preventing further distal movement of thedrive member 124.

As shown in FIG. 23, a lockout reset opening 229 is provided in thehousing 120 of the body portion 102 of the stapler reload 100 to permitoverriding of the lockout assembly 220. In particular, a tool, e.g.,screw driver 234, may be received through the lockout reset opening 229and engaged with a distal portion 224 b of the lockout member 224, asindicated by arrow “D”, to pivot the proximal portion 224 a of thelockout member 224 from engagement with the flange 232 (FIG. 22) of thedrive member 124, as indicated by arrow “E”.

With reference briefly to FIGS. 24-26, as described above, the firstarticulation link 126 is releasably coupled to an articulation mechanism(not shown) of the adapter assembly 30 (FIG. 1) to control articulationof the tool assembly 106. More specifically, when the articulationmechanism of the adapter assembly 30 is operated, the first articulationlink 126 is advanced (or retracted) to cause corresponding advancement(or retraction) of the second articulation link 138. The distal portionof the second articulation link 138 engages a first articulation member140 a which is pivotally connected to the pin member 182 a of the lowermounting bracket 142 of the mounting assembly 104. As shown in FIG. 26,the pin member 182 a is positioned at a location offset from thelongitudinal axis of the body portion 102 such that longitudinalmovement of the first articulation member 140 a effects pivotal movementof the tool assembly 106 about a perpendicular axis, as indicated byarrow “F” in FIG. 24.

A second articulation member 140 b is positioned parallel to the firstarticulation member 140 a and engages the pin member 182 b of the lowermounting bracket 142 of the mounting assembly 104. Each of the first andsecond articulation members 140 a, 140 b includes a curved supportsurface 141 a, 141 b, respectively, for supporting blow out plates 250which extend between the body portion 102 and the tool assembly 106 ofthe stapler reload 100.

With reference to FIGS. 27-29, the stapler reload 100 includes apnuematic seal 240 for creating a seal around the drive member 124 andthe second articulation link 138. The pnuematic seal 240 includes acircular base portion 240 a and a flange portion 240 b extending fromthe base portion 240 a. The base portion 240 a is configured to fluidlyseal a proximal portion of the inner body 144 of the small diameterportion 112 of the body portion 102 of the stapler reload 100. Theflange portion 240 b engages a proximal portion of the inner body 144 ofthe small diameter portion 112 of the body portion 102. The pnuematicseal 240 defines a central opening 241 a for accommodating the drivemember 124 in a sealing manner. The pnuematic seal 240 further defines anotch 241 b for accommodating the second articulation link 138. Thepnuematic seal 240 is disposed within the inner body 144 of the smalldiameter portion 112 of the body portion 102 and creates a seal betweeneach of the drive member 124 and the second articulation link 138 andthe inner body 144.

With reference now to FIGS. 30-34, the mounting assembly 104 of thestapler reload 100 includes the upper and lower mounting brackets 162,142, and first and second coupling members 178, 180. As noted above, thefirst and second coupling members 178, 180 each include an opening 179,181, respectively, for receiving pivot members 142 a, 162 a ofrespective lower and upper mounting brackets 142, 162. Moreparticularly, each of the openings 179, 181 of the first and secondcoupling members 178, 180, respectively, include a notch 179 a, 181 a(FIG. 31) that receives the tab 142 b, 162 b (FIG. 30; shown in phantom)extending from the respective pivot members 142 a, 162 a of the upperand lower mounting brackets 162, 142. In this manner, each of the firstand second coupling members 178, 180 is received about the respectivepivot members 142 a, 162 a with the respective notches 179 a, 181 a ofthe respective first and second coupling members 178, 180 aligned withthe respective tabs 142 b, 162 b of the respective pivot members 142 a,162 a. The first and second coupling members 178, 180 are rotated froman unlocked position (FIG. 33), in which the first and second couplingmembers 178, 180 are disposed perpendicular to the longitudinal axis “x”of the stapler reload 100, to a locked position (FIG. 34) in which thefirst and second coupling members 178, 180 are disposed in alignmentwith the longitudinal axis “x” to secure the first and second couplingmembers 178, 180 to the respective lower and upper mounting brackets142, 162. In this manner, the mounting assembly 104 creates a rivetlesspivot assembly for articulating the tool assembly 106 of the staplerreload 100 relative to the body portion 102.

As described above, each of the upper and lower housing sections 120 a,120 b of the body portion 102 include cutouts 145 a, 145 b (FIG. 5).Each of the first and second coupling members 178, 180 include foldedportions 178 a, 180 a that are received within the cutouts 145 a, 145 b.The folded portions 178 a, 180 a of the respective first and secondcoupling members 178, 180 increase the strength of the engagement withthe respective upper and lower half-sections 144 a, 144 b of the innerbody 144 of the small diameter portion 112 of the body portion 102 ofthe stapler reload 100.

Referring to FIG. 35, in embodiments, the drive assembly 136 is formedfrom a plurality of stacked sheets 136 a-d of a resilient material,e.g., stainless steel, spring steel. The distal portion of each of thesheets 136 a-d of material of the drive assembly 136 is secured to thedynamic clamping member 156 a such as by welding. The proximal ends ofsheets 136 a-d are hook-shaped and are received in the slot 125 in thedistal portion of the drive member 124 such that longitudinal movementof the drive member 124 effects longitudinal movement of the driveassembly 136.

As best shown in FIG. 35, the dynamic clamping member 156 a includes aknife 156 b supported or formed on a vertical strut 158 of the dynamicclamping member 156 a. The dynamic clamping member 156 a includes anupper flange 158 a and a lower flange 158 b. The upper flange 158 a ispositioned to be slideably received within the cavity (not shown) of theanvil assembly 114 and the lower flange 158 b is positioned to beslideably positioned along an outer surface 164 a (FIG. 37) of thechannel 164 of the cartridge assembly 116. In embodiments, either orboth of the dynamic clamping member 156 a and the channel 164 arelubricated with a hard coating. Distal movement of the drive assembly136 initially advances the lower flange 158 b into engagement with a camsurface 164 b formed on the channel 164 to pivot the cartridge assembly116 towards the anvil assembly 114 to a closed or approximated position(FIG. 38).

Thereafter, advancement of the drive assembly 136 progressively definesa maximum tissue gap between the anvil assembly 114 and cartridgeassembly 116 adjacent the dynamic clamping member 156 a as the dynamicclamping member 156 a moves through the tool assembly 106. Inembodiments, at least portions of the dynamic clamping member 156 aand/or channel 164 are formed from and/or coated with a frictionreducing material to minimize the force required to fire the surgicalstapler 10 by facilitating substantially frictionless passage of thedynamic clamping member 156 a through the stapler reload 100. For adetailed description of an exemplary drive assembly and dynamic clampingmember, please refer to the '965 publication, the content of which waspreviously incorporated herein.

With reference to FIG. 38, a blow-out plate 250 is positioned on eachside of the drive assembly 136 to prevent buckling of the drive assembly136 during straight and articulated firing of the stapler reload 100.The blow-out plates 250 extportion between the body portion 102 and thetool assembly 106 of the stapler reload 100. A distal portion 250 b ofeach of the blow-out plates 250 is fixedly secured to the lower mountingbracket 142 of the mounting assembly 104. In embodiments, the distalportion 250 a of each of the blow-out plates 250 is press fit within aslot (not shown) formed in the lower mounting bracket 142 (shown inphantom in FIG. 30) to axially fix the distal portion 250 b of each ofthe blow-out plates 250 to the lower mounting bracket 142. Each of thefirst and second articulation members 140 a, 140 b includes curvedportions 141 a, 141 b, respectively, for supporting an outer surface ofthe blow-out plates 250.

When the drive assembly 136 is advanced to advance the dynamic clampingmember 156 a through the cartridge body 170 to fire staples “S” with thetool assembly 106 in an articulated position, the blow-out plates 250prevent the drive assembly 136 from buckling outward.

Turning to FIGS. 40 and 41, the sled 176 is supported within thecartridge body 170 at a position immediately distal of the dynamicclamping member 156 a. The distal portion of the dynamic clamping member156 a is positioned to engage and drive the sled 176 through thecartridge body 170 of the cartridge assembly 116. The sled 176 includesfirst and second cam members 176 a, 176 b that are positioned to engagethe pushers 174 positioned within the cartridge assembly 116 to ejectthe staples “S” from the cartridge body 170. Each pusher 174 supportstwo staples “S” positioned on one side of the knife slot 171 b of thecartridge body 170. As noted above, the cartridge assembly 116 includesthe cartridge shield 172 for retaining the pushers 176 within thecartridge body 170. More particularly, the cartridge shield 172 allowsthe pushers 176 to be floating, and prevents the pushers 174 fromexiting the staple retention slots 171 a during transport.

With reference now to FIGS. 42-44, the surgical stapler 10 is configuredto distribute actuation forces along a load path which enables thestapler reload 100 to have a smaller diameter. The load path begins withthe knife 156 b (FIG. 35) of the dynamic clamping member 156 a (FIG. 35)of the drive assembly 136 (FIG. 35) cutting through tissue (not shown).More specifically, in the presently disclosed surgical stapler 10, theload is transferred from the dynamic clamping member 156 a to the anviland cartridge assemblies 114, 116 as the dynamic clamping member 156 atravels therethrough. The load is then transferred from the anvil andcartridge assemblies 114, 116 to the lower mounting bracket 142 by pivotpins 168. The first and second pivot members 142 a, 162 a of therespective lower and upper mounting brackets 142, 162 of the mountingassembly 104 transfer the load from the lower and upper mountingbrackets 142, 162 to the first and second coupling members 178, 180. Thefirst and second coupling members 178, 180 transfer the load to theinner body 144 of the small diameter portion 112 of the body portion 102of the stapler reload 100.

With particular reference now to FIG. 42, the inner body 104 of thesmall diameter portion 112 of the body portion 120 of the stapler reload100 defines a cutout 253 for receiving a dinking plate 254. The dinkingplate 254 is positioned to engage a dinking lance 256 located on theouter tube 146 of the small diameter portion 112 of the body portion 102of the stapler reload 100. The dinking plate and lance 254, 256 operateto transfer the load from the inner body 104 of the small diameterportion 112 of the body portion 102 to the inner housing 120 of thelarge diameter portion 110 of the stapler reload 100. The inner housing120 transfers the load to the actuation device 20 (FIG. 1) via theadapter assembly 30 (FIG. 1).

Persons skilled in the art will understand that the devices and methodsspecifically described herein and illustrated in the accompanyingdrawings are non-limiting exemplary embodiments. It is envisioned thatthe elements and features illustrated or described in connection withone exemplary embodiment may be combined with the elements and featuresof another without departing from the scope of the present disclosure.As well, one skilled in the art will appreciate further features andadvantages of the disclosure based on the above-described embodiments.Accordingly, the disclosure is not to be limited by what has beenparticularly shown and described, except as indicated by the appendedclaims.

What is claimed is:
 1. A surgical stapler comprising: an actuationdevice; a stapler reload releasably secured to the actuation device, thestapler reload including a body portion, a tool assembly, and a driveassembly extending between the body portion and the tool assembly, thebody portion including a large diameter portion defining a firstdiameter and a small diameter portion defining a second diameterextending distally from the large diameter portion, the tool assemblybeing supported on a distal portion of the small diameter portion,wherein the small diameter portion is dimensioned to pass through an 8mm trocar; and a shipping lock releasably secured to the large diameterportion of the body portion and engagable with the drive assembly forpreventing longitudinal movement of the drive assembly.
 2. The surgicalstapler according to claim 1, wherein the tool assembly includes ananvil assembly and a cartridge assembly supporting a plurality ofstaples and the drive assembly is movable through the body portion andthe tool assembly to eject staples from the cartridge assembly.
 3. Thesurgical stapler according to claim 1, wherein the drive assemblyincludes a drive member and the shipping lock includes a locking pin,the locking pin being received through the drive member when theshipping lock is secured to the body portion to prevent longitudinalmovement of the drive member.
 4. The surgical stapler according to claim3, further including a locking plate, wherein the locking plate engagesthe locking pin prior to the stapler reload being secured to theactuation device.
 5. The surgical stapler according to claim 4, whereinthe locking plate is configured to disengage from the locking pin whenthe stapler reload is properly secured to the actuation device.
 6. Thesurgical stapler according to claim 5, further including a lockingsleeve received about a proximal portion of the body portion of thestapler reload, wherein rotation of the locking sleeve from a firstposition to a second position moves the locking plate out of engagementwith the locking pin.
 7. The surgical stapler according to claim 6,wherein the locking sleeve rotates from the first position to the secondposition when the stapler reload is properly secured to the actuationdevice.
 8. The surgical stapler according to claim 3, wherein theshipping lock includes curved arms configured to frictionally engage thebody portion of the stapler reload.
 9. A surgical stapler comprising: anactuation device; a stapler reload releasably secured to the actuationdevice, the stapler reload including a body portion, a tool assembly,and a drive assembly extending between the body portion and the toolassembly, the body portion including a large diameter portion defining afirst diameter and a small diameter portion defining a second diameterextending distally from the large diameter portion, the tool assemblybeing supported on a distal portion of the small diameter portion,wherein the small diameter portion is dimensioned to pass through an 8mm trocar; and a lockout assembly received within the body portionconfigured to prevent advancement of the drive assembly following anactuation of the stapler reload, the lockout assembly including alockout shield and a lockout member, wherein the lockout shield ismovable from a first position to a second position to prevent engagementof the lockout member with the drive assembly prior to the actuation ofthe stapler reload, wherein the lockout member engages the driveassembly when the lockout shield is in the second position.
 10. Thesurgical stapler of claim 9, wherein the drive assembly includes a drivemember having a ridge, the lockout member being engagable with the ridgewhen the lockout shield is in the second position.
 11. The surgicalstapler of claim 10, wherein the lockout shield is disposed about theridge when in the first position and is spaced from the ridge when inthe second position.
 12. The surgical stapler of claim 11, wherein thelockout shield is disposed within the large diameter portion when in thefirst position and is disposed within the small diameter portion when inthe second position.
 13. The surgical stapler of claim 12, wherein thelockout shield includes at least one lance and the large diameterportion includes a housing, the lance being configured to engage thehousing when in the second position to prevent proximal movement of thelockout shield.
 14. The surgical stapler of claim 12, wherein thelockout member is pivotally supported within the body portion between afirst condition in engagement with the drive member and a secondcondition disengaged from the drive member.
 15. The surgical stapler ofclaim 13, wherein the lockout member includes at least one fingerfrictionally engaged with the drive member when the lockout shield is inthe first position to maintain the lockout shield in the first position.